Apparatus for stripping and unloading a molded part from a mold core

ABSTRACT

Disclosed is a method and apparatus for continuously molding plastic parts. Basically, the apparatus comprises a pair of spaced, rotatable, indexable trunnion transfer units or wheels having a plurality of cradles thereon for receiving and transporting carrier bars. The wheels are indexable to a number of stations at which various activities take place and are positioned on either side of the mold area of a conventional molding machine. A carrier bar having affixed thereto a plurality of cores for the part to be molded, for example, is transported by the rotating wheel from the bottom of the first wheel to a first station where an insert may be added to the core and thence to the top position of the wheel where the carrier bar is transferred to a conveyor which in turn transports the carrier bar to the mold. After completion of the molding cycle, the carrier bar with the molded parts thereon, is transported by the conveyor to the top of the second wheel where it is inserted thereon. The second wheel is then rotated to a first station where additional parts may be affixed to the molded part and thence to a second station where the molded parts are unloaded from the cores on the carrier bar. After unloading, the parts are moved by conveyor or other means for further processing or are deposited in a storage container. Thereafter, the second wheel is indexed to a third station where the empty carrier bar is transferred to an inclined track for return to the first wheel where the process is repeated. The method and apparatus can be employed to transport a carrier bar having either cores or inserts thereon depending upon the part to be molded.

[22] Filed:

Redmer et al.

[ Nov. 18, 1975 1 APPARATUS FOR STRIPPING AND UNLOADING A MOLDED PART FROM A MOLD CORE [75] Inventors: Wilbert Redmer, Boca Raton;

Kenneth Rolin, Del Ray Beach; Herman Nittel, Boca Raton, all of Fla.

[73] Assignee: Abbott Laboratories, North Chicago, 111.

Dec. 13, 1974 [21] Appl. No.: 532,557

Related US. Application Data [62] Division of Ser. No. 241,934, April 7, 1972.

[52] US. Cl 425/436 R; 425/274; 425/517; 425/126 S [51] Int. Cl. B29C 7/00 [58] Field of Search 425/436 R, 274, 506, 517, 425/317, 324 R, DIG. 201, 126 S, 221, 214

[56] References Cited UNITED STATES PATENTS 429,957 6/1890 Reinhold 425/274 1,960,456 5/1934 Robb 425/436 X Primary ExaminerRobert L. Spicer Attorney, Agent, or Firm-Gildo E. Fato; Robert L. Niblack [57] ABSTRACT Disclosed is a method and apparatus for continuously molding plastic parts. Basically, the apparatus comprises a pair of spaced, rotatable, indexable trunnion transfer units or wheels having a plurality of cradles thereon for receiving and transporting carrier bars. The wheels are indexable to a number of stations at which various activities take place and are positioned on either side of the mold area of a conventional molding machine. A carrier bar having affixed thereto a plurality of cores for the partto be molded, for example, is transported by the rotating wheel from the bottom of the first wheel to a first station where an insert may be added to the core and thence to the top position of the wheel where the carrier bar is transferred to a conveyor which in turn transports the carrier bar to the mold. After completion of the molding cycle, the carrier bar with the molded parts thereon, is transported by the conveyor to the top of the second wheel where it is inserted thereon. The second wheel is then rotated to a first station where additional parts may be affixed to the molded part and thence to a second station where the molded parts are unloaded from the cores on the carrier bar. After unloading, the parts are moved by conveyor or other means for further processing or are deposited in a storage container. Thereafter, the second wheel is indexed to a third station where the empty carrier bar is transferred to an inclined track for return to the first wheel where the process is repeated. The method and apparatus can be employed to transport a carrier bar having either cores or inserts thereon depending upon the part to be molded.

2 Claims, 42 Drawing Figures ,so 45 -uq lj U.S. Patent Nov. 18, 1975 Sheet20f 16 3,920,374

Sheet 3 0f 16 3,920,374

US. Patent Nov. 18, 1975 TRANSFER TO CONVEYOR NEEDLE FEED PIC-3.7

' SHOT Pm I SMALL WHEEL SHOT PIN LARGE WHEEL I l M @1m.@ @w T 91 v H W11 9 @wlWw 6 8 m F ,US. Patent Nov. 18, 1975 Sheet 9 of 16 3,920,374

U.S. Patent Nov. 18, 1975 Sheet 10 of 16 3,920,374

KSHEATH DROP Fl&.30 114- US. Patent Nov. 18,1975 Sheet 11 of 16 3,920,374

FIG. 3|

BAR Era-ens a no EE E 5 m K an \L a a FIL 4 v I 5 7 6 OcLocK RETURN US. Patent Nov. 18,1975 Sheet 12 of 16 3,920,374

FlG.34-

U S. Patent Nov. 18, 1975. Sheet 13 of 16 3,920,374

FIG.35

FIG.36

ASSEMBLY ROOM U.S..Patent Nov. 18, 1975 Sheet 14 of 16 3,920,374

U.S. Patent Nov. 18,1975 Sheet 15 of 16 3,920,374

US. Patent Nov. 18,1975 Sheet-16 of 16 3,920,374

APPARATUS FOR STRIPPING AND UNLOADING A MOLDED PART FROM A MOLD CORE BACKGROUND OF THE INVENTION This is a division of application Ser. No. 241,934 filed Apr. 7, 1972.

It is desirable in the molding of plastic parts to produce such parts at a high production level. One method of obtaining a high production rate is to employ a molding machine with a plurality of cooperating or mating mold parts. As described in US. Pat. No. 3,309,739 for a plastic injection molding machine, the molds can be mounted on a shuttle table so that one set of mold parts are closed and the mold cavity therein injected with plastic to form the desired part while one or more other sets of molds are available for cooling, removal of finished parts and loading into the mold cavity of any special part or insert. The shuttle table is then moved to align the mold with an injection station in the molding machine while the mold which has just been injected with plastic is moved to an ejecting station. Each mold may contain a plurality of cavities so that with each injection of plastic, a plurality of parts are formed. While such a method and apparatus is generally satisfactory, to further increase the production level, additional machines are required which in turn require additional operators.

SUMMARY OF THE INVENTION In essence, the method of the present invention and the apparatus for conducting the method comprises a pair of rotatable, indexable trunnion transfer units or wheels which may be indexed to a number of stations at which various activities take place. A carrier bar having positioned thereon a plurality of cores, for example, is positioned on the first wheel at the bottom thereof. The wheel is then indexed to a first station where inserts are fed into the cores after which the wheel is indexed to a second station at the top of the wheel where the carrier bar is transferred from the wheel to a conveyor. The conveyor transports the carrier bar to the mold where molding of the plastic part takes place. After the molding cycle is completed, the carrier bar with the molded parts thereon is transported by the conveyor to the top of the second wheel and transferred from the conveyor to the wheel. The second trunnion transfer unit or wheel is then indexed to a first station where additional parts can be added to the molded part and again indexed to a second position where the molded parts and removed from the core and deposited on a conveyor for further processing or into a storage container. The second wheel is finally indexed to a fourth position so that the empty carrier bar is positioned at the bottom of 'the wheel in an inverted position. The bar is then transferred to an inclined track down which it slides to the first wheel wherein the process is repeated.

The carrier bar can be designed to transport either cores or inserts depending on the part to be made.

eration of the following detailed description of a spe-- cific embodiment thereof, when read in conjunction with the appended drawings, in which:

FIG. 1 is a perspective view of the molding apparatus of the present invention;

FIG. 2 is a perspective view of a carrier with mold cores projecting therefrom, the carrier being transported through the apparatus for molding and fabrication of a plastic part;

FIG. 3 is a side elevational view in cross-section illustrating a syringe barrel made with the method and apparatus of the present invention;

FIG. 4 is a top plan view of the apparatus illustrating the position of the various portions thereof;

FIG. 5 is a side plan view of the apparatus of FIG. 4 illustrating the position of the various portions thereof and the transport of the carrier through the apparatus during the molding of a part;

FIG. 6 is a side elevational view of the first trunnion transfer unit or wheel, partly in cross-section, and illustrating the position needle feeding station in relation to the trunnion transfer unit;

FIG. 7 is a top elevational view of a shot-pin assembly used to accurately align the trunnion transfer units;

FIG. 8 is a side elevational view of the shot pin assembly of FIG. 7;

FIG. 9 is a side elevational view of the return track and elevator assembly for returning a carrier from the second trunnion transfer unit to the first trunnion trans fer unit;

FIG. 10 is a side elevational view in cross-section of the return track assembly with a carrier thereon;

FIG. 11 is a top plan view of the needle feeding and loading assembly, illustrating the needle feeding, clamping, and loading assemblies;

FIG. 12 is a side elevational view, partially in crosssection of the needle feeding, clamping, and loading assemblies;

FIG. 13 is a rear elevational view, partially in crosssection of the needle hopper and shuttle, taken along the line 13-13 of FIG. 11;

FIG. 14 is a side elevational view in cross-section of the needle hopper and shuttle assembly;

FIG. 15 is a partial top elevational view illustrating the needle clamping and releasing assembly;

FIG. 16 is a side elevational view in cross-section taken along the line l616 of FIG. 15;

FIG. 17 is a side elevational view in cross-section taken along the line 1717 of FIG. 15 and illustrating the needle clamp assembly;

FIG. 18 is a side elevational view in cross-section illustrating the needle clamp detail;

FIG. 19 is a top elevational view of the carrier ejector assembly as positioned on the first trunnion transfer unit;

FIG. 20 is a front elevational view of the carrier ejector assembly taken along the line 2020 of FIG. 19;

FIG. 21 is a side elevational view of the carrier ejector assembly of FIG. 19;

FIG. 22 is a partial side elevational view illustrating the chain driving and stopping mechanism;

FIG. 23 is a partial side elevational view illustrating the chain stopping mechanism detail;

FIG. 24 is a front elevational view of the chain stopping mechanism of FIG. 23;

FIG. 25 is a top elevational view of the up drum;

FIG. 26 is a top elevational view illustrating the sheath orienting slot in the orientation escapement and sheath pickillustrating orientation of the sheaths prior to transfer FIG. 28 is a top elevational view of the sheath loading assembly;

FIG. 29 is a rear elevational view of the sheath loading assembly taken along the line 29-29. of FIG. 28;

FIG. 30 is a side elevational view, partially in crosssection, of the sheath loading assembly taken along the line 30-30 of FIG. 28;

FIG. 31 is a side elevational view of the second trunnion transfer unit illustrating the position of the sheath feeding, unloading and carrier ejection stations in relation to the trunnion transfer unit and illustrating a portion of the part transport tubes and conveyor;

FIG. 32 is a top elevational view of the transport tubes positioned on the conveyor for transporting the molded parts;

FIG. 33 is a top elevational view of the molded part unloading assembly for stripping the molded parts from the cores on the carrier;

FIG. 34 is a side elevational view of the unloading and stripping assembly in FIG. 33;

FIG. 35 is a top elevational view of the transport tubes positioned on the part conveyor and a portion of the part unloading and stripping assembly;

FIG. 36 is a side elevational view, partially in crosssection, of the assembly of FIG. 35;

FIG. 37 is a side elevational view of the part conveyor and part transfer assembly illustrating transfer of the molded parts from the transfer tubes on the conveyor to the part transfer assembly;

FIG. 38 is a rear elevational view, partially in crosssection, of the conveyor and part tranport tubes taken along the line 3838 of FIG. 37;

FIG. 39 is a front elevational view, partially in crosssection, of the part transfer assembly of FIG. 37;

FIG. 40 is a side elevational view, partially in crosssection, of the part transfer assembly of FIG. 35;

FIG. 41 is a side elevational view, partially in crosssection, of a part in which the carrier employed in the method and apparatus of this invention has cores projecting therefrom;

FIG. 42 is a top elevational view of a molded part made by the method and apparatus of this invention and in which the carrier transports the insert;

GENERAL DESCRIPTION The method and apparatus 40 of this invention can be employed to produce plastic parts of various types. Depending upon the part to be molded, a carrier bar 50 which is transported through the apparatus 40 as hereinafter described can be designed to transfer either cores or inserts thereon as required by the part to be formed. To produce a part 45 such as illustrated in FIG. 3, the carrier 50 can be designed to transport mold cores 51 and inserts 48 for the part. Thus, the parts 45 are molded about the core 51 and the insert 48. On the other hand, the carrier 50 can be designed to transport the insert 31 only when a part 30 such as illustrated in FIG. 42 is to be molded. For such a part 30, the carrier 50 transports the insert 31 to the mold where the plastic material 32 is injected about the insert 31. The apparatus of the present invention is portable and can be utilized with a conventional molding machine 99 such as a Hydraulic Press Manufacturing Company molding machine having a 14 ounce capacity and a 200 ton clamp.

A general understanding of the method and apparatus 40 can be attained by reference to FIGS. 1, 2, 4, and which illustrate the over-all apparatus. While the method and apparatus 40 can be utilized to fabricate avariety of plastic parts, for convenience the system will be described with reference to the production of the injector or barrel portion 40 of a syringe 45 as illustrated in FIG. 3. The syringe 45 comprises a barrel 46 including a hub 47 which is molded about a cannula or needle 48. A sheath 49 is inserted onto the hub 47 of the barrel 46 to protect the needle 48 prior to use. The carrier 50 is accordingly designed for production of the injector 45 and includes a plurality of cores 51 shaped to conform with the barrel 46 and hub portion 47 of the injector 45 and projecting from the base 53 of the carrier 50. A cylindrical opening 52 in the cores 51 receives and supports the needle 48 prior to molding.

As best seen in FIG. 1, the apparatus comprises a first trunnion transfer unit positioned on one side of the molding machine 99 and a second trunnion transfer unit positioned on the opposite side of the molding machine 99. A movable chain assembly transports the carrier 50 from the first trunnion transfer unit 70 through the molding machine 99 where the part is molded to the second trunnion transfer unit 75 where additional parts such as the sheath 49 can be added and the part stripped from the cores 51 on the carrier 50. The empty carrier 50 is then conveyed from the second trunnion transfer unit 75 by means of a return track assembly 250 to an elevator assembly 260 which transfers the carrier 50 to the first trunnion transfer unit 70 where the process is repeated.

To produce the injector 45, a suitable carrier 50 having cores 51 thereon as previously described is inserted at the 6 oclock position of the first trunnion transfer unit 70. The trunnion 70 is then rotated to the 3 oclock position where a needle feeding assembly 100 inserts needles 48 into the opening 52 of the cores 51. The trunnion 70 is then rotated to the 12 oclock position where the carrier 50 is ejected onto the chain assembly 130. The carrier 50 with the loaded needles 48 in the cores 51 is then conveyed to the molding machine 99 where the mold is closed about the cores 51 and the plastic injected. The mold is then opened and the carrier 50 with the molded parts 45 thereon is conveyed to the second trunnion transfer unit 75 where the carrier 50 is loaded onto the transfer unit 75 at the 12 oclock position thereof. The transfer unit 75 is further rotated in a clockwise direction to the 3 oclock position where sheaths 49 are inserted onto the hub 47 of the injector 45. The sheaths 49 which are previously molded are stored in a hopper and are fed to an orientation excapement 151. Here the sheaths 49 are oriented into a proper position as hereinafter explained and fed to a sheath feeder assembly which loads the sheaths 49 onto the barrel 46. of the injector 45. The transfer unit 75 is then rotated to the 5 oclock position where the molded parts 45 are stripped from the cores 51 of the carrier 50. The parts 45 can then be conveyed to other equipment for further processing or may be collected in suitable containers. The transfer unit 75 is subsequently rotated to the 6 oclock position where the carrier 50 in an inverted position is ejected onto the return track assembly 250 and is conveyed to the elevator 260. The carrier 50 is then inserted into the first trunnion transfer unit 70 and the process is repeated.

The trunnion transfer wheels 70, 75 are indexed by means of a l2-stop Geneva-drive. Geneva drives are conventionally utilized for indexing purposes and are described in Mechanisms and Dynamics of Machinery, 2nd Edition by Mabie and Ocvirk at pages 32 and 33.

Referring to FIGS. 6, 7, and 8, FIG. 6 illustrates the first trunnion transfer wheel 70. Transfer wheel 70 includes l2 spaced cradles 71 positioned evenly around the periphery of the trunnion transfer unit 70 which receive and support the carrier 50 as they are transported by the wheel 70 to the various positions. In the operation of the apparatus, the trunnion transfer units 70, 75 are advanced with an intermittent rotary motion, the distance of each interval of advance being such as to move each cradle 71, 76 into the position previously occupied by the one immediately ahead of it. This intermittent advance of the trunnion transfer units 70, 75 is effected by a Geneva-drive 'and clutch and brake combination (not shown). In the embodiment illustrated, the trunnion transfer units 70, 75 are indexed by using a l2-stop Geneva-drive being driven by a reducer and electric clutch-brake. The Geneva-drive is coupled to an electric motor by a clutch, the output from the clutch driving a gear-reducer through a brake. By a simultaneous releasing of the clutch and engaging of the brake, transmission may be effectively instanteously stopped. The output from the gear-reducer drives a Geneva-drive input gear which has a driving pin projecting from its outer edge. The Geneva-drive results from the meshing of the pin with corresponding slots in a Geneva-drive output gear. While the input gear rotates uniformly and at a constant speed, power is transmitted to the Geneva-drive output gear intermittently because the pin moves inwardly and outwardly in the slots-for part of its travel and is then ineffectual to rotate the gear. The intermittent drive is transmitted to the trunnion transfer unit 70, 75. FIG. 7 and 8 illustrate a shot-pin assembly 55 which accurately lines up the trunnion transfer units 70, 75 at the various positions. On a signal produced, for example, after the needles 48 are fed into the cores 51, as hereinafter explained, a latching relay holds the contacts of the motor control relay closed. A lobe on the shot-pin cam 56 (FIG. 7) energizes another relay which in turn breaks the connection to the motor drive and the wheel 70, 75 is stopped as the brake is released. While the Genevadrive clutch and brake combination stops the transfer wheel 70, 75 at the desired position, a shot-pin assembly 55 is utilized to accurately align the wheel at the proper position. The shot-pin assembly 55 basically comprises a cam 56, a cam follower 57, arm 58 and shot-pin 59. Each station on the trunnion transfer unit 70, 75, corresponding to the position of a cradle 71, 76 includes a bushing (not shown) for engagement with the pin 59. The pin 59 is tapered and as the wheel 70, 75 stops at each station, the pin 59, activated by the cam 56, follower 57, and arm 58 enters a bushing and accurately lines up the wheel. The shot-pin assembly 55 is supported by a plate 60 positioned adjacent the trunnion transfer units 70, 75, the arm 58 thereof pivoted in the center on a pin 61 at the end of a bracket 62 extending from the support plat 60. Likewise, the shotpin 59 is pivoted to the arm 58 on the side opposite the cam follower 57 by pivot pins 63 on the end thereof and on the arm 58, the pins 63 connected by a link 64.

The shot-pin 59 reciprocates through a bushing 65- which passes through the plate 60; a spring 66 acting to assist the insertion of the shot-pin 59 in the trunnion transfer units. Each wheel is driven separately by its own drive and signals.

RETURN TRACK AND ELEVATOR ASSEMBLY After the molding process is completed and the parts are unloaded from the carrier 50 as hereinafter explained, the carrier 50 is ejected from the second transfer unit onto the return track 250 in an inverted position. Referring to FIGS. 5, 9, and 10, the return track 250 lies in an inclined position and connects the bottom or 12 oclock position of the second trunnion transfer units 75 with the elevator assembly 260 and comprises a pair of spaced channel beams 251 affixed to-frame member 256. Opposed rollers 252 are affixed to the channel beams 251 along the length thereof by means of bolts 253 and permit the carriers 50 to slide along the length of the return track 250, the base 53 being supported by the rollers 252 and the cores 51 depending through the space between the opposed rollers 252. Accordingly, the carriers 50 are transported from the second trunnion transfer unit 75 along the return track 250 to the elevator assembly 260. To provide additional support for the return track 250, tie bars 255 are positioned at intervals along the length thereof, affixed to a pair of opposed depending brackets 254, the other ends of which are fastened to the channel beams 251. The elevator assembly 260 comprises a support frame 261 which receives the carriers 50. The carrier transfer member 262 is normally in an inclined position in line with the return track 250 and depends by means of pivot 263 from a horizontal plate 265 and is supported on the opposite end by a shoulder 266 affixed to and projecting from the support frame 261. A bracket 264 projects from the transfer member 262 through an opening 267 in the plate 265. The bracket 264 is gripped for transfer of the entire assembly as hereinafter explained. As the carrier 50 arrives at the carrier transfer assembly 262 in the elevator 250, it activates a switch 271. The switch 271 in turn activates an air cylinder 268 which includes a reciprocating plunger 269 and a gripping head 270. The head 270 of the air cylinder 268 engages with the bracket 264 of the carrier transfer assembly 262 and the cylinder 268 reverses direction to transport the transfer assembly 262 and carrier 60 in a vertical direction. The transfer assembly 262 is first pivoted into a horizontal position and then transferred to the top of elevator assembly 250, in line with the cradle 71 at the 6 oclock position of the first trunnion transfer unit 70, where a switch 262 is engaged. The switch 262 activates the air cylinder 263 and the head 264 thereof pushes the carrier 50 onto the first trunnion transfer unit 70 at the 6 oclock position thereof.

NEEDLE FEEDING AND LOADING After the carrier is loaded onto the first trunnion transfer wheel 70 at the 6 oclock position thereof, the

wheel 70 is rotated in a counterclockwise direction, as previously described, to the 3 oclock position to a needle feeding station. With a needle 48 having a point on either end, care must be exercised so that the points are not damaged. Accordingly, the needles 48 cannot be dropped or pushed into the openings 52 in the cores 51. A clamp assembly 102 is therefore used to feed the needles 48 into the cores 51. The needle feeding and loading assembly basically comprises a hopper and feeding assembly 101 for feeding the needles 48 to a clamp assembly 102 and an air cylinder 103 for transferring the needles 48 from the clamp assembly 102 to the cores 51. The entire needle feeding and loading as- 

1. Apparatus for stripping and unloading a molded part from a mold core, said apparatus comprising: a pair of opposed, pivoted jaws for gripping, stripping and releasing of the molded part from the core, oNe of said jaws having a bar connected thereto by a pivot, the other end of the bar being connected to means for drawing back and releasing the bar to thereby close and open the jaw, said bar having a curved depression in the bottom thereof; the other of said jaws having a base plate at the bottom thereof projecting toward the opposite jaw, the projecting portion having a curved surface on the top thereof for mating with the curved depression in the bottom of the pivot bar so that as the pivoted bar is drawn back, the curved surface on the base plate of the jaw rides on the bottom surface of the pivoted bar to open the jaw when it rides in the curved depressison in the bottom of the bar and to close the jaw when it rides on the flat surface on the bottom of the bar to ultimately close the opposed jaws to engage the molded part so that the molded part is held firmly in the opposed jaws for removal of the part from the core, and to open the jaws when the bar is released after the part is removed from the core.
 2. The apparatus of claim 1 wherein said unloading apparatus is mounted on a support plate, the plate being movable toward and away from the core from a gripping and removal position to a releasing position. 